Manufacture of sections of fiber-plastic compound materials

ABSTRACT

The method for the manufacture of sections of fiber-plastic compound materials is carried out by means of at least one draw nozzle ( 10 ). In this nozzle, fibers ( 41 ) which are impregnated with flowable plastic ( 42 ) are formed under pressure to a product ( 41 ) with a predetermined cross-section and consolidated with the withdrawal of heat. The cross-sectional surface of the draw nozzle is periodically increased and decreased in time in its entire shape imparting region, with a value for the frequency of the oscillating cross-sectional surface being chosen less than 1 kHz, preferably less than 100 Hz.

[0001] The invention relates to a method for the manufacture of sections of fibre-plastic compound materials in accordance with the preamble of claim 1 and to a plant for carrying out the method.

BACKGROUND OF THE INVENTION

[0002] By means of a continuous process, which is called pultrusion, sections can be manufactured of reinforcement fibres which are impregnated with plastics (see e.g. V. Kerbiriou “Imprägnieren und Pultrusion von thermoplastischen Verbundprofilen”, VDI-Verlag, Düsseldorf 1997). The plastic is distributed between the fibres in the method in such a manner that a tight, pore-poor polymer matrix arises. The matrix consists of the plastic (matrix polymer) in the form of a largely homogeneous phase which is embedded between the fibres. As a starting product (semi-finished product) one advantageously uses bandlets, mixed fibres, powder impregnated fibre bundles or fibre bundles which are impregnated with flowable plastic which are manufactured from a compound material and which are already consolidated. Thermoplastics or duromers (to the extent that these are not yet hardened and are thus flowable) come under consideration for matrix polymers. In the pultrusion of compound materials with solid thermoplastics, for example the named bandlets, the plastics must first be melted. The fusion viscosity amounts to about 500 to 1000 Pa s. Known draw off speeds, by means of which the compound materials are drawn through a nozzle, amount to up to 6 m/min. Greater speeds lead to losses in the pultrate quality as a result of faulty compression, insufficient distribution of the matrix polymer and/or fibre breakage.

[0003] A plant for carrying out a pultrusion comprises a supply device for the starting product, an oven, a nozzle (draw or shaping nozzle) and a draw off device, with the nozzle having a continuously narrowing cross-section in a shapeimparting region. The nozzle is slightly overfilled with the starting product so that a matrix flow-back within the fibre bed which is formed by the fibres takes place. The permeability of the fibre bed is anisotropic. The matrix flow takes place mainly along the fibres, but also transverse to the latter, through which the largely homogeneous distribution of the matrix polymer over the entire cross-section of the section which is to be achieved first results. Due to the matrix flow-back the fibre volume proportion increases in the nozzle and a surplus of plastic forms at the nozzle entry, which drips off there.

SUMMARY OF THE INVENTION

[0004] The object of the invention is to provide a method for the manufacture of sections of fibre-plastic compound materials which permits a substantially higher production rate in comparison with known pultrusion methods. This object is satisfied by the method which is characterised in claim 1.

[0005] The method for the manufacture of profiles of fibre-plastic compound materials is carried out by means of at least one draw nozzle. In this nozzle, fibres which are impregnated with flowable plastic are shaped under pressure to a product with a predetermined cross-section and consolidated with the withdrawal of heat. The cross-sectional surface of the draw nozzle is periodically increased and decreased in time in its entire shape imparting region, with a value for the frequency of the oscillating cross-sectional surface being chosen to be less than 1 kHz, preferably less than 100 Hz.

[0006] Subordinate claims 2 to 7 relate to advantageous embodiments of the method in accordance with the invention. The subject of claims 8 to 10 is a plant for carrying out the method.

[0007] In the course of the method in accordance with the invention, phases during which the pressing is done with a narrow nozzle cross-section alternate periodically with phases during which the nozzle cross-section is expanded so that the pressing pressure is strongly reduced. At the beginning of the pressing phase the matrix component is relative large; it subsequently decreases due to a matrix flow-back which is caused by the pressing. During the pressing phase the draw off forces are substantially lower in comparison with the known pultrusion when the comparison is made at the same draw off speeds. Therefore a greater draw off speed can be chosen in the method in accordance with the invention at which the draw off forces are just as large as in the known pultrusion. Also, at a thus increased draw off speed no loss of quality arises.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The invention will be explained in the following with reference to the drawings. Shown are:

[0009]FIG. 1 a plant for carrying out the method in accordance with the invention,

[0010]FIG. 2 a longitudinal section through a draw nozzle in accordance with the invention,

[0011]FIG. 3 a front view of the same draw nozzle,

[0012]FIG. 4 a cross-section through a fibre reinforced thermoplastic band,

[0013]FIG. 5 a mesh of such bands,

[0014]FIG. 6 a perspective illustration of the shape imparting region of a draw nozzle in accordance with the invention,

[0015]FIG. 7 a draw nozzle in accordance with the invention of which the movable part is designed to be pivotal,

[0016]FIG. 8 cross sections through special draw nozzles,

[0017]FIG. 9 diagrams for the explanation of the method in accordance with the invention with reference to an idealised method in which the drawing off is interrupted during a predetermined period,

[0018]FIG. 10 corresponding diagrams with longitudinal fusion distributions in the fibre-plastic compound material during the reshaping in the draw nozzle in accordance with the invention,

[0019]FIG. 11 diagrams for a method in accordance with the invention in which the draw off speed is a constant and

[0020]FIG. 12 a draw nozzle with protective films.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

[0021] The plant which is schematically illustrated in FIG. 1 comprises a partial plant 1 which contains at least one draw nozzle, a partial plant 2 by means of which a starting product is supplied and a draw off device 3 by means of which a produced section 41 is drawn off. The starting product consists of a large number of fibre reinforced bands 4 which are drawn off from supply rolls 20. These elements 4 of the starting product are heated up in an oven 21 by means of hot air or thermal radiation. The matrix polymer can in this be liquefied. In a region at the input side of the draw nozzle the thermoplastic temperature can be further influenced by a controlled heat exchange, for example further increased, so that a not yet melted matrix polymer liquefies. It can however also if the matrix polymer is already present as a fusion at the nozzle input be cooled so that during the compression and shaping a consolidation already begins from the direction of the section edges. The elements 4 of the starting product can be brought into contact with one another between the oven 21 and the draw nozzle of the partial plant 1 through deflection about pins 22, 22′. A thus produced strand 40 with elements 4 which adhere to one another is subsequently compressed and shaped in the nozzle.

[0022] A draw off speed vB, which is predetermined with the draw off device 3, can be constant or designed to be variable corresponding to the periodically varying degree of opening of the draw nozzle. A control device 31 can be provided between the partial plant 1 and the draw off device 3 for the adjusting between a variable draw-off speed and the time dependent degree of opening of the draw nozzle.

[0023]FIGS. 2 and 3 show a first embodiment of a draw nozzle 10 which is contained in the partial plant 1 of the plant in accordance with the invention of FIG. 1. The draw nozzle 10 is assembled from two mutually movable parts 11 and 12, which bound an inner space 13. The upper part 12 with the inner surface 123, 123′ is designed to be movable. Two drives 14, 14′ with bars 15 which are vertically displaceable by a travel 132 execute a transversal movement perpendicular to the draw off direction, namely a parallel displacement of the surface 123. The periodically varying nozzle cross-section oscillates between two states with cross-sectional surface which in each case remain largely constant, namely a state with a wide cross-section (surface 123 in the upper position) and a state with a narrow cross-section (surface 123′ in the lower position). The drives 14, 14′ produce a transversal oscillation 150 with a frequency for which a value which is less than 1 kHz, for example 10 Hz, is chosen. This oscillation can for example be driven with a cam mechanism, with electromagnets or piezoelectrically. The drives 14, 14′ are stably mounted on a carrier 16 between two side walls 11′ and 11″ which form a rigid unit with the lower nozzle part 11.

[0024] The inner space 13 of the nozzle 10 has an inlet 130 which contracts in the draw off direction and an outlet 131 which expands in the example shown. In the region of the inlet 130 a heating can be integrated in the wall of the nozzle 10. In the rear part the nozzle is designed as a cooler in which the produced section 41 (FIG. 1) is consolidated with a withdrawal of heat. The front part can also be designed as a cooler when a sufficient heating of the starting product 40 is provided in the oven 21.

[0025] The drives 14, 14′ can also be designed in such a manner that a movement can be executed in which a longitudinal movement 151, 152 is superimposed on the transversal movement 150, with this longitudinal movement 151 being directed in the draw direction (vB) when the nozzle is in the state with a narrow cross-section. The draw off movement can be assisted with a longitudinal movement 151, 152 of this kind.

[0026] The cross-section illustrated in FIG. 4 through a unidirectionally fibre reinforced thermoplastic band 4 which is illustrated in FIG. 4 shows its inner structure with fibres 41 which form a fibre bed which is tightly impregnated with a polymer matrix. A mesh 5 assembled of such bands 4 see FIG. 5 can also be used as a starting product of the method in accordance with the invention.

[0027]FIG. 6 illustrates perspectively the inlet 130 with the adjoining shape imparting region 13 of the draw nozzle 10 in accordance with the invention. The U shaped lower part 11 forms with its flanks 11′ and 11″ a guide for the movable upper part 12 which is fitted in tightly but in a manner so as to be capable of sliding between the flanks 11, and 11″. The arrows 4′ indicate the supply of the starting material, which can be supplied from different directions with the speed vB. For the following explanations an x axis in the draw off direction, a z axis in the direction of the transversal movement and a point A at the input-side end of the inner surface 123 are indicated.

[0028] The transversal movement of the movable part 12 can also be a pivotal movement: see FIG. 7. The centre of rotation of this pivotal movement in the centre of the bearing 120 must be arranged at the output side at a distance from the narrowest nozzle cross-section. Thanks to this position of the centre of rotation the nozzle cross-section contracts in the draw direction at any degree of opening, and at every position of the shape imparting nozzle region the nozzle cross-section is variable. Advantageously only one drive is provided (only drive rod 15 illustrated).

[0029] Sections of rectangular cross-section can be manufactured most simply. Other cross-sections are also possible, as is illustrated in FIG. 8: e.g. hexagonal or also indicated in chain dotting U shaped ones (inner surface 123″ of part 12).

[0030] The method in accordance with the invention shall be explained with respect to the matrix flow-back with the diagrams of FIGS. 9 and 10 for an idealised method. In this idealised method the drawing off is interrupted during a predetermined duration of the period. The upper diagram of FIG. 9 represents the degree of opening of the draw nozzle by means of the z coordinate of the point A in FIG. 6, zA. During the first phase with the duration t1 t1 the nozzle is in the state with a wide cross-section; during the remaining duration of the period t2, t2, the nozzle is in the state with the narrow cross-section, thus the pressing phase, is present. The corresponding pressing pressure p is shown in the middle diagram. During the first phase no pressing is done; during the second, pressing is done with a constant pressure. The drawing off is illustrated—see lower diagram—as proceeding with constant speed vB for the state with the wide nozzle cross-section. During the pressing state the drawing off is stopped.

[0031]FIG. 10 shows corresponding diagrams for the distribution of the matrix proportion M in the fibre fiber-plastic compound material in the x direction (cf. FIG. 6) along the shape imparting region of the nozzle. Prior to entry into the nozzle, M is constant, which is illustrated in the upper diagram of FIG. 10 with a horizontal line 420. As a result of the matrix flow-back there follows a region with an increased matrix proportion, which is illustrated with a curve piece 421. This curve piece 421 is intended to reproduce the matrix distribution at the end of the pressing phase. The hatched surface F+ corresponds to a surplus of matrix in the shape-imparting region of the nozzle. During the nozzle state with a wide cross-section the curve piece 421 is displaced in the x direction by the distance vB t1 t1.

[0032] In the lower diagram of FIG. 10 the displaced curve piece is designated with the reference symbol 421″. During the subsequent pressing phase this curve piece deforms as a result of the matrix flow-back. After a continuous passing through of intermediate forms 421′, the shape 421, which is drawn in in the upper diagram, results again at the end of the period. The above named diagram displacement vB t1 t1 corresponds to a backwardly backward moving displacement of the left flank of the curve piece 421″ or 421′ respectively by a distance v+ t2 t2, with v+ signifying a flow-back speed. As one sees, a flow-back which that is caused by the pressing is compensated by means of the displacement of the unpressed compound material during the first phase. Thus no matrix flow-back takes place on the time average.

[0033] The matrix surplus F+ is located in the shape-imparting region of the draw nozzle, thus at the place where reshaping forces arise. The surplus matrix acts as a lubricant so that the reshaping forces are reduced relative to those of a corresponding pultrusion with a nozzle cross-section which that is held constant. It is thus sensible to continue the drawing off also during the pressing phase. Since the matrix surplus enables an increase of the draw off speed relative to the known pultrusion thanks to its lubricating action so that an acceleration of the method results.

[0034]FIG. 11 shows qualitatively and corresponding to FIG. 9 for a constant draw off speed vB how the pressing pressure p (lower diagram) varies in dependence on a variable degree of opening of the nozzle (upper diagram). Here a press shaping is also generally accomplished during the first phase in which however. During the first phase, a surplus of matrix polymer is transported along in the draw off direction (x direction) thanks to the enlarged nozzle cross-section 50 that on. On the average only a very slight matrix surplus or none at all arises.

[0035] For a concrete By way of example, namely the manufacture of a section from unidirectionally unidirectional carbon-fibre fiber reinforced thermoplastic bands (CFK/PA12) with vB=10 m/min (=const) and at a frequency of 10 Hz it is to be stated which length is to be provided for the shape can be used. In this example, the shape-imparting region of a nozzle which is held at 240° C. From a static pressing experiment (with 7 bands, each 0.8 mm thick, 15 mm wide, fibre fiber content 65 vol %, pressure 10 bar) it is known that for the pressing time a duration of about 2 s is required. The pressing phase extends over about ⅔ of the period, which lasts 0.1 s. From these data it can be derived that the desired length of the nozzle must amount to about 500 mm.

[0036] In the illustrated exemplary embodiments only the upper part of the draw nozzle is designed to be movable. The lower part could also be movable in addition and be provided with a separate drive. In a mirror-imaged construction of the nozzle and nozzle parts which that are moved in a contrary manner, possible problems with excitable eigen-frequencies of the nozzle arrangement (nozzle and frame) can be circumvented.

[0037] It is particularly advantageous when an ultrasonic oscillation with a frequency of grater than 10 kHz is superposed on the nozzle of the plant in accordance with the invention with an additional drive. From for example U.S. Pat. No. 5,091,036 it is known that the ultrasonic oscillation improves the flowing of the matrix polymer so that the pultrusion is favourably favorably influenced.

[0038] Instead of a single draw nozzle a plurality of draw nozzles which are placed one after the other can also be used for a multi-stage reshaping process. This is required in the manufacture of complicated section shapes.

[0039] In an additional heating of the product in the nozzle there is the danger that the melted matrix polymer sticks to the surface of the shaping nozzle region. As is indicated in FIG. 12, a sticking of the product can be prevented by means of co-moving protective films 240 (rolls 241, 242). In the method in accordance with the invention protective films of this kind can be relatively easily employed in contrast to the known pultrusion methods.

[0040] Advantageously a periodic variation of the nozzle cross-section between two states with a cross-sectional surface which that remains largely constant in each case takes place in the method in accordance with the invention. The speed with which the product is drawn through the nozzle can be held approximately constant. Or this product speed can be varied in dependence on the state of the cross-section and indeed in such a manner that the speed at a wide cross-section is substantially greater, in particular by at least a factor of two, than at a narrow cross-section. In a largely constant product speed a shorter duration t1 t1 (FIG. 11) is advantageously predetermined for the phase in which the cross-section expands or the state with the wide cross-section is present than for the duration t2 t2 of the complementary phase, which forms the remaining part of the period.

[0041] In the described exemplary embodiments the draw nozzles contract in the direction of the oscillation, i.e. the direction of movement of the movable part. The nozzle can however also be designed in such a manner that a contraction transverse to the oscillation direction is present. (cf. FIG. 6) along the shape imparting region of the nozzle. Prior to entry into the nozzle, M is constant, which is illustrated in the upper diagram of FIG. 10 with a horizontal line 420. As a result of the matrix flow-back there follows a region with an increased matrix proportion, which is illustrated with a curve piece 421. This curve piece 421 is intended to reproduce the matrix distribution at the end of the pressing phase. The hatched surface F+ corresponds to a surplus of matrix in the shape imparting region of the nozzle. During the nozzle state with a wide cross-section the curve piece 421 is displaced in the x direction by the distance v_(B) Δt₁.

[0042] In the lower diagram of FIG. 10 the displaced curve piece is designated with the reference symbol 421″. During the subsequent pressing phase this curve piece deforms as a result of the matrix flow-back. After a continuous passing through of intermediate forms 421′, the shape 421, which is drawn in in the upper diagram, results again at the end of the period. The above named diagram displacement v_(B) Δt₁ corresponds to a backwardly moving displacement of the left flank of the curve piece 421″ or 421′ respectively by a distance v+ Δt₂, with v+ signifying a flow-back speed. As one sees, a flow-back which is caused by the pressing is compensated by means of the displacement of the unpressed compound material during the first phase. Thus no matrix flow-back takes place on the time average.

[0043] The matrix surplus F+ is located in the shape imparting region of the draw nozzle, thus at the place where reshaping forces arise. The surplus matrix acts as a lubricant so that the reshaping forces are reduced relative to those of a corresponding pultrusion with a nozzle cross-section which is held constant. It is thus sensible to continue the drawing off also during the pressing phase. Since the matrix surplus enables an increase of the draw off speed relative to the known pultrusion thanks to its lubricating action so that an acceleration of the method results.

[0044]FIG. 11 shows qualitatively and corresponding to FIG. 9 for a constant draw off speed v_(B) how the pressing pressure p (lower diagram) varies in dependence on a variable degree of opening of the nozzle (upper diagram). Here a press shaping is also generally accomplished during the first phase in which however a surplus of matrix polymer is transported along in the draw off direction (x direction) thanks to the enlarged nozzle cross-section so that on the average only a very slight matrix surplus or none at all arises.

[0045] For a concrete example, namely the manufacture of a section from unidirectionally carbon-fibre reinforced thermoplastic bands (CFK/PA12) with v_(B)=10 m/min (=const) and at a frequency of 10 Hz it is to be stated which length is to be provided for the shape imparting region of a nozzle which is held at 240° C. From a static pressing experiment (with 7 bands, each 0.8 mm thick, 15 mm wide, fibre content 65 vol %, pressure 10 bar) it is known that for the pressing time a duration of about 2 s is required. The pressing phase extends over about ⅔ of the period, which lasts 0.1 s. From these data it can be derived that the desired length of the nozzle must amount to about 500 mm.

[0046] In the illustrated exemplary embodiments only the upper part of the draw nozzle is designed to be movable. The lower part could also be movable in addition and be provided with a separate drive. In a mirror-imaged construction of the nozzle and nozzle parts which are moved in a contrary manner, possible problems with excitable eigen-frequencies of the nozzle arrangement (nozzle and frame) can be circumvented.

[0047] It is particularly advantageous when an ultrasonic oscillation with a frequency of grater than 10 kHz is superposed on the nozzle of the plant in accordance with the invention with an additional drive. From for example U.S. Pat. No. 5,091,036 it is known that the ultrasonic oscillation improves the flowing of the matrix polymer so that the pultrusion is favourably influenced.

[0048] Instead of a single draw nozzle a plurality of draw nozzles which are placed one after the other can also be used for a multi-stage reshaping process. This is required in the manufacture of complicated section shapes.

[0049] In an additional heating of the product in the nozzle there is the danger that the melted matrix polymer sticks to the surface of the shaping nozzle region. As is indicated in FIG. 12, a sticking of the product can be prevented by means of co-moving protective films 240 (rolls 241, 242). In the method in accordance with the invention protective films of this kind can be relatively easily employed in contrast to the known pultrusion methods.

[0050] Advantageously a periodic variation of the nozzle cross-section between two states with a cross-sectional surface which remains largely constant in each case takes place in the method in accordance with the invention. The speed with which the product is drawn through the nozzle can be held approximately constant. Or this product speed can be varied in dependence on the state of the cross-section and indeed in such a manner that the speed at a wide cross-section is substantially greater, in particular by at least a factor of two, than at a narrow cross-section. In a largely constant product speed a shorter duration Δt₁ (FIG. 11) is advantageously predetermined for the phase in which the cross-section expands or the state with the wide cross-section is present than for the duration Δt₂ of the complementary phase, which forms the remaining part of the period.

[0051] In the described exemplary embodiments the draw nozzles contract in the direction of the oscillation, i.e. the direction of movement of the movable part. The nozzle can however also be designed in such a manner that a contraction transverse to the oscillation direction is present. 

1. Method for the manufacture of profiles of fibre-plastic compound materials by means of at least one draw nozzle (10) in which fibres (41) which are impregnated with flowable plastic (42) are formed under pressure to a product (41) with a predetermined cross-section and consolidated with the withdrawal of heat, characterised in that the cross-sectional surface of the draw nozzle is periodically increased and decreased in time in its entire shape imparting region, with a value for the frequency of the oscillating cross-sectional surface being chosen to be less than 1 kHz, preferably less than 100 Hz.
 2. Method in accordance with claim 1 characterised in that a large number of unidirectionally fibre reinforced thermoplastic bands (4) or meshes (5) of such bands (4) are used as the starting product; in that these elements (4, 5) of the starting product are heated up in an oven (21) by means of hot air or thermal radiation prior to entry into the draw nozzle (10) so that the thermoplastic (42) in particular liquefies; and in that the thermoplastic temperature is further influenced in an input-side region of the draw nozzle.
 3. Method in accordance with claim 2 characterised in that the elements (4, 5) of the starting product are brought into contact with one another between the oven (21) and the draw nozzle (10); and in that a thus produced strand (40) is drawn into the nozzle with elements which adhere to one another.
 4. Method in accordance with one of the claims 1 to 3 characterised in that the periodically varying nozzle cross-section oscillates between two states with cross-sectional surface which in each case remain largely constant—namely a state with a wide cross-section and a state with a narrow cross-section; and in that the speed (v_(B)) with which the product (40, 41) is drawn through the nozzle (10) is held approximately constant or that this product speed (v_(B)) is varied in dependence on the state of the cross-section so that the speed at the wide cross-section is substantially greater, in particular at least by a factor of two, than at the narrow cross-section.
 5. Method in accordance with claim 4 characterised in that at a largely constant product speed (v_(B)) for the phase in which the cross-section expands or the state with a wide cross-section is present a shorter duration (Δt₁) is predetermined than for the duration (Δt₂) of the complementary phase, which forms the remaining part of the period.
 6. Method in accordance with one of the claims 1 to 5 characterised in that a sticking of the product to the shaping surface (123) of the draw nozzle (10) is prevented by means of co-moving protective films (12).
 7. Method in accordance with one of the claims 1 to 6 characterised in that an ultrasonic oscillation with a frequency greater than 10 kHz is superimposed on the periodic cross-section variation with a frequency less than 1 kHz.
 8. Plant for carrying out the method in accordance with one of the claims 1 to 7 comprising a supply device (20) with the starting product (4, 5), an oven (21), a draw nozzle (10) and a draw off device (3), with the nozzle having a continuously narrowing cross-section in a shape imparting region, characterised in that the draw nozzle is assembled from two mutually movable parts (11, 12), with in particular only one of these parts (12) being designed to be movable; and in that with at least one drive (14, 15) a transversal movement (150), namely a parallel displacement or a pivotal movement of the movable part can be carried out perpendicular to the draw direction (v_(B)), with its centre of rotation (120) being arranged at the output side at a distance from the narrowest nozzle cross-section in the case of a pivotal movement.
 9. Plant in accordance with claim 8 characterised in that a movement can be carried out with the drive (14, 15) in which a longitudinal movement (151, 152) is superimposable on the transversal movement, with this longitudinal movement (151) being directed in the draw direction (v_(B)) at the narrow cross-section.
 10. Plant in accordance with claim 8 or claim 9 characterised in that a control device (31) is arranged between the drive (14) for the movable part (12) and the draw off device (3) by means of which the draw off speed (v_(B)) can be adjusted to the opening state of the nozzle (10). 